Hello guys,
First time attempting to build a helmet of any kind. Made the first test fit helmet out of paper, just to see how well it fit. Turned out to be a bit too small for me so I scaled the whole thing up 3%. Worked out nice.

Then I used sticker paper to print out the templates (thank you everyone who has created templates and posted them to share, KUDOS!!!)
Used an electric disc cutter and a jig saw to get then all cut out.

I don't think I've ever seen anyone do it this way. That's pretty impressive.

Mar 18, 2013

gt8mar

Re: WIP: First helmet build, using sheet metal

Sweet!

Mar 22, 2013

TrevOwnz

Re: WIP: First helmet build, using sheet metal

I've always wanted a Boba Fett helmet that was made of steel or even bulletproof like a soldiers helmet. A full field grade suit would be the ultimate dream haha.

Keep it up. Can't wait to see the finished look.

Mar 25, 2013

SCauntay

3 Attachment(s)

Re: WIP: First helmet build, using sheet metal

Thanks guys, haven't had the most time to work on my helmet. I did get all the pieces cut out and spent some time on the keyhole thingie for the back.

Mar 28, 2013

xose421

Re: WIP: First helmet build, using sheet metal

This looks so awesome... can't wait to see it finish and polished up.
:thumbsup

Mar 31, 2013

SCauntay

4 Attachment(s)

Re: WIP: First helmet build, using sheet metal

Got the left ear piece done, started to work on the range finder. All of it is still in the very rough mock up stage.

Apr 1, 2013

Wolfsburg

Re: WIP: First helmet build, using sheet metal

That is just incredible!

Apr 1, 2013

RafalFett

Re: WIP: First helmet build, using sheet metal

WOW! You did a great job with my helmet templates! I know that is a bit hard to do the ears and the rangefinder from scratch (using cardboard or sintra), but seeing that you did all this using metal sheets, you have my deepest respect and admiration! Just keep up with the already awesome work!

Apr 2, 2013

SCauntay

Re: WIP: First helmet build, using sheet metal

Yeah, they are super tricky. I get a bit anal about the evenness and proportions, so I've been grinding and doing filler welds, then grinding those down. My range finder "mast" is a bit off, so I might redo that one. It's actually going pretty well, no huge snags yet, but it's still early. Funnest project I've done in a while. Thanks for the support, it's really keeping the motivation going.

Keep on keepin' on.......

Apr 6, 2013

darkartist81

Re: WIP: First helmet build, using sheet metal

This is amazing... I can't believe you are doing this with sheet metal. Serious credit for tackling something like this, and for being so **** good at it. I really looks fantastic so far.

Apr 15, 2013

SCauntay

Re: WIP: First helmet build, using sheet metal

Haven't abandoned the project, just had to put it on the back burner for a bit. I'll be doing some work on it this week.

Apr 22, 2013

WookieeHunter

Re: WIP: First helmet build, using sheet metal

That is incredible work so far. Going to be keeping a close eye on this thread for sure, have been thinking of doing the same thing but with aluminium as i have loads at home, have started doing some mock up body armour to see how i gt on. Think its time to print out some templates though. Inspiring stuff, respect to you sir!

Apr 28, 2013

SCauntay

3 Attachment(s)

Re: WIP: First helmet build, using sheet metal

Aluminum would be awesome, go for it!

A tiny update, I just welded a few seams. The helmet has taken the back burner for a while. But It'll get a good go next week.

Was doing some touch ups and tacking some spots on the dome, then I realized I made the lower "ear" section below the range finder backwards!!!!!!! haha, minor set back, I'll get a better one made as soon as I get the time.

Ok, it's been some time now. Didn't abandon the project, other things had to come first. Anywho, go the dome slightly tacked to the bucket, the left ear tacked up, remade the right ear piece correctly, and test fit one of the computer chip boards in the keyhole thingie.

Got a little bit more done today. Box to add onto the keyhole section to allow it to recess into the helmet a tad, more tacking and adjusting the dome to the bucket, range finder lower ear piece tacked up.

I have a bunch of pictures, but have to get them all organized. So here are a few of the most significant ones. Still need to do more of the detail, but that will be done a little later. First picture is after I used a torch to burn off all of the remaining stickers. Attachment 70350Attachment 70351Attachment 70353Attachment 70352

Jul 31, 2013

SCauntay

Re: WIP: First helmet build, using sheet metal

Now in the plans are some goodies. The suit is next. After much thinking and balancing on the fence about this, I've fallen off to the side of using sheet metal for the armor as well. Again, all of my work has been made much easier thanks to all of the hard work of all those that have put in the time and effort into creating templates. Thank you guys.

Aug 3, 2013

Jigglenomicon

Re: WIP: First helmet build, using sheet metal

This is super awesome!
i hope you have a really strong neck tho , that thing must weigh a ton ^^

Sep 9, 2013

azurelloyd

Re: WIP: First helmet build, using sheet metal

Thats what i plan to do next. My armor is already metal but my plaster\bondo\beerbox lid suffered catostrophic dent enlargment. i,ll post some pics of my plates. what did you ddo the welding with. what guage and what mat.?